www.energyabsorption.com
Revision B December 2013
www.highwayguardrail.com
35
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Electrical Problems
Caution!!!
Remove all Rings, Watches, Etc. Prior to Doing Any Electrical
Work!!!
Operating DC (direct current) power units efficiently requires proper voltage. Any attempt to
operate below the minimum required voltage could cause system failure.
A. Signals which point to low voltages are:
1. Motor running at reduced speed.
2. Solenoid valves not shifting.
B.
Minimum voltage readings are as follows:
1. The minimum voltage between the motor stud and ground is 9.0 volts at maximum
load conditions.
2. The minimum voltage between the valve solenoid power wire (''hot wire'') and ground
is 9.5 volts at maximum load conditions.
C. Causes for low voltage are:
1. Battery capacity too small.
2. Cable ends not electrically secured to battery cable. (Solder them if necessary)
3. Battery cable size too small for load and length of run. Copper #2 automotive battery
cable is the recommended minimum size. Larger copper battery cable (#1, #0 or
#00) may be required for cable lengths over 30 feet to keep performance from
deteriorating.
4. Grounding is established through the pump mounting bolts. Clean any dirt, or rust
from mounting holes and bolts to achieve proper ground.
5. Bad joints where cable ends are bolted to battery, motor solenoid, start switch,
ground, etc.
6. Burnt contacts on motor solenoid or start switch.
D. Check for low voltage as follows: (A DC voltmeter will be required.)
1. On vehicles equipped with an alternator, the voltage should be approximately 13.5
volts with no electrical accessories operating and the engine running - Check it
2. Operate pump under maximum conditions. Use the voltmeter to probe each
connection, cable end, and cable from the battery all the way back to the motor stud
and note the voltage losses. Make necessary repairs. Increase the voltage above the
minimum required.
Note:
Check the ground side as well: paint, rust, and dirt are insulators - remove them.
